The Best Tool Available for Learning Machinery Diagnosis

To gain an in-depth understanding of different vibration signatures, controlled experiments on a device that emulates real world machinery are needed. While analysis of a single machinery fault may be beneficial, there are many occasions when the analysis of the interaction between dynamic stiffness, resonance, and speed is essential in order to gain an understanding of real world vibration spectra.
With the MFS, the expertise required to diagnose industrial machinery problems in well controlled experiments can be developed and enhanced. With a plant running at full production, it is virtually impractical to gain an understanding of the kinetics and dynamics of machinery without adversely affecting production and profits: The MFS enables offline training and experimentation which in turn will minimize production downtime.

Validate balancing procedures above and below the first critical resonance.

Smart Design Makes the Simulator Robust and Easy to Use

The MFS is designed to be both versatile and easy to operate. The simulator is constructed with a split bracket bearing housing, a sliding shaft, rotors with split collar ends, couplings, pulleys, a multiple belt tensioning and gearbox mounting mechanism, and reciprocating system; all of which are designed to be easily removed and replaced between various experiments.

Built-in tachometer with LCD display and one pulse per revolution analog TTL output for DAQ purposes

Voltage

115/230 VAC, Single phase, 60/50 Hz

Mechanical

Shaft Diameter

3/4″ diameter; Turned, Ground, & Polished (TGP) steel

Bearing

Two sealed rolling element in aluminum horizontally split bracket housing for easy changes, tapped for transducer mount. Bearing mounts can be mounted in five different position for variable rotor span

16 BNC connector plate under the rotor base linked to BNC connector panel mounted on the edge for the base plate for direct connection to data collectors

Power leads accessible for current measurements.

Impact resistant clear safety cover with safety interlock

Balance weight kit

Allen wrench set

24V Power supply

Cover support

Comprehensive operations manual

The MFS provides a basic setup for performing experiments and learning vibration signatures of different machine malfunctions. However, a detailed investigation of particular and more advance vibration phenomena or machinery fault will require additional attachments and fixtures which are available through optional kits.

Training Curriculum Manual (SQI-TRCM)

The training curriculum manual begins with textbook and basic classroom training in the fundamentals of classic machinery vibration, transducers, monitoring, signal processing, analysis, etc; from beginner to upper intermediate levels. It is both hands-on and mathematically oriented, being appropriate for both technicians and engineers.

A wide array of laboratory exercises to be conducted on the MFS to provide a truly experiential learning environment.

Use as a basis for accelerated course preparation and the development of vibration training program.

Eccentric Rotor (Requires MR-SCK-3/4) (M-ER-3/4)

Learn the effects of rotor eccentricity on vibration spectra.

Determine relationships between eccentricity and unbalance.

Develop techniques to locate and correct the effects of eccentricity.

Learn the effect of varying the mass moment of inertia on vibration amplitude.

The kit consists of one aluminum rotor with an asymmetrically located center and one clamp collar.

Cocked Rotor (Requires MR-SCK-3/4) (M-CR-3/4)

Learn the effects of a sheave that has not been fitted to the shaft properly.

Learn vibration signature of a cocked rotor.

Develop methods to correct cocked rotor problems.

Learn the effect of varying the mass moment of inertia on vibration amplitude.

The kit consists of a cocked aluminum rotor (0.5 degree off-axis) and one clamp collar.

Coupling Type Set (Requires MR-SCK-3/4) (M-CK-3/4)

Learn the effects of coupling stiffness on rotor dynamics and vibration signature.

Clarify the complexities of machinery shaft misalignment problems (spectral pattern for shaft misalignment is a strong function of coupling stiffness).

The kit consists of one gear, one LoveJoy, one rubber, and one rigid steel coupling.

Observe the difficulty associated with attempting to balance an overhung rotor on a bent shaft.

Learn to cope with the alignment issues due to a bent shaft.

The kit consists of one 3/4″ shaft coupling-end bent ~0.010″

Rolling Bearing Resonance/Critical Study Kit (M-RSK-1/2)

Study resonance and critical speed phenomena, at speeds below 2000 RPM to simulate real world operating conditions while improving safety. The standard 3/4″ shaft has a high resonance frequency, 7000 RPM or more depending on rotor positions.

Study damaging effects of resonance and develop control methods.

Relocate rotors and supports to study the effects of mass and stiffness on resonance frequencies and mode shapes.

Study beating due to closely spaced modes.

Study non-linear dynamics for chaos modeling.

The kit consists of one ½” shaft, three rotors, two rolling element bearings, and one coupling.

Sleeve Bearing Resonance Study Kit (M-SBK-1/2)

Study resonance and critical speed phenomena in sleeve bearings.

The kit consists of two customized grease-lubricated, babbitt lined sleeve bearings, two bearing pedestals, and various thickness plastic shims

Requires M-RSK-1/2

3/4″ shaft bearing loader (Requires MR-SCK -3/4) (M-BL-3/4)

Investigate bearing radial loading effects.

Enhance the spectral amplitude of system.

The kit consists of one 3/4″ bore loader weighting 11lb (5kg) and two clamp collars.

Learn the effects of the frequency and amplitude modulation on vibration spectra.

Remove the pinion assembly for backlash adjustment, and fault introduction.

The kit consists of two V-belts, two double groove sheaves and one rolling tensioner; one three-way oil-lubricated gearbox with straight cut bevel gears, cup and cone roller bearings; and one manually adjustable magnetic brake.

Defective Straight Tooth Gearbox Pinions (Requires M-BDGB) (M-DGPA)

Study the effect of damaged tooth in gearboxes.

Investigate backlash between mating gears.

The kit consists of one missing tooth pinion and one chipped tooth pinion.

Study the effect of different head and valve restriction on suction and/or discharge sides on flow dynamics of the pump.

Investigate the effect of speed and load variation on pump vibration spectra.

Study the effect of clearance between the impeller and the suction portion of the pump.

Conduct similar studies using other non-hazardous liquids of different viscosity and specific gravity.

The kit consists of one single stage centrifugal pump, one LEXAN cover for visualizing cavitation, two pressure gauges, one flow meter, one water tank, all connecting valves and hoses, one sheave, and mounting hardware

Learn to relate the vibration signature to forces associated with common malfunctions such as resonance and bearing faults. Learn phase relationship between force and vibration spectrum.

Learn nature of rotor dynamic forces due to common defects.

Witness 180 degree phase shift between heavy and high spots when rotor goes through a critical speed. Demonstrate how mass unbalance force quadruples when the speed is doubled, but vibration amplitude does not follow the same trend.

The kit consists of one transducer simultaneously measuring vertical and horizontal force and one matching signal conditioner.

Axial Bearing Force Transducer for 1/2″ to 1″ shafts (M-FTA)

Measure the axial load on the main shaft under dynamic excitation.

Investigate the effect of misaligned shaft and belts on the shaft axial load.

Study the effects of cocked rotors and eccentric sheaves on the shaft axial load.

The kit consists of one transducer measuring axial force on main shaft and one matching signal conditioner.

High Value Combination Packages

The MFS provides a basic setup for performing experiments and learning vibration signatures of different machine malfunctions. However, a detailed investigation of particular and more advance vibration phenomena or machinery fault will require additional attachments and fixtures which are available through optional kits. Depending on the package selected, you get a 6% to 12% discount over separately purchased items.

Spectra Quest, Inc. is dedicated to providing state-of-the-art systems for enhancing product reliability and quality assurance. We develop and manufacture training and diagnostic systems for industrial maintenance and vibration analysis. Our flagship Machinery Fault Simulator (MFS) has been sold in over 50 countries [ Read More About Us]

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